Resin materials for making three-dimensional objects and methods of using the same

ABSTRACT

A polymerizable liquid that can be used for producing three-dimensional objects by methods of additive manufacturing is disclosed. The polymerizable liquid may comprise: (a) a blocked or reactively blocked polyurethane prepolymer; (b) (optional) a reactive diluent; (c) a blocked or reactively blocked curing agent; (d) a photoinitiator; and (e) (optional) a blocked or reactively blocked diisocyanate. The method using such polymerizable liquid to form three-dimensional objects is also described.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of International Application No.PCT/CN 2020/095715, field on Jun. 12, 2020, which claims priority toU.S. Provisional Patent Application No. 62/861,240, filed on Jun. 13,2019, U.S. Provisional Patent Application No. 62/942,678, filed on Dec.2, 2019, and U.S. Provisional Patent Application No. 62/982,154, filedon Feb. 27, 2020, the entire contents of each of which are herebyincorporated by reference.

TECHNICAL FIELD

This disclosure relates generally to polymerizable resin materials andmethods of using the same for manufacturing three-dimensional objects.

BACKGROUND

Photopolymerization 3D printing technology uses photopolymerizableresins as raw materials, and solidifies such liquid photopolymerizableresins under visible or ultraviolet light irradiation. Thephotopolymerizable resin is generally in a liquid state, and itundergoes photopolymerization under irradiation of visible orultraviolet light of a certain wavelength to complete curing. In atypical photopolymerization 3D printing process, the three-dimensionalobject is built up one layer at a time. Each layer is formed byprojecting a two-dimensional pattern for that layer into aphotopolymerizable liquid, thus curing the liquid to form a solid shapethat matches the two-dimensional pattern. The pattern typically isdisplayed on a programmable display, such as those based on LCD (liquidcrystal display) or DLP (digital light processing, which is based ondigital micromirror devices) technologies. The pattern is projected byoptics from the display device onto the liquid. Because the displaydevice is programmable, the pattern on the display can be changed fordifferent layers.

In conventional photopolymerization 3D printing process, two type ofprinting techniques are commonly used, top-down printing and bottom-upprinting. In the “top-down” printing, the photopolymerizable resin iscured by a light source placed above the resin reservoir on a buildplatform where the 3D object is cured and attached to. Once the currentlayer is cured, the build platform is lowered down into the resinreservoir for the next layer. Each new layer is formed on the uppersurface of the 3D object to be formed. By contrast, in the “bottom up”printing, the photopolymerizable resin is cured through alight-transmissive window in the bottom of the resin reservoir by alight source from below. Each new layer is formed on the bottom surfaceof the 3D object to be formed. In “bottom-up” printing, the buildplatform is raised out of the resin reservoir and a ‘peel’ step isrequired between each layer in order to detach the cured layer from thebottom surface of the resin reservoir. Continuous Liquid InterfaceProduction (CLIP) is one of bottom-up 3D printing techniques wherephotopolymerizable resin is cured through an oxygen permeable window inthe bottom of the resin reservoir by a light source from below. Theoxygen layer (called as “dead zone” or “inhibition layer”) over thewindow keeps the liquid resin from sticking to the bottom surface of theresin reservoir and continuous light exposure can be utilized because no‘peel’ step is required. However, this type of printing technique alsohas its limitations. For example, the dead zone is highly temperaturesensitive and minor temperature fluctuation may cause the print to fail.

U.S. Pat. No. 9,676,963 disclosed a method of forming athree-dimensional object using a polymerizable liquid comprising amixture of a first light polymerizable liquid component and a secondsolidifiable component that is different from the first component.However, such method uses a mixture of at least two different componentsand the viscosity will significantly increase after the two componentsare mixed together since some components may solidify prematurely. As aresult, the three-dimensional printing process must start within hoursof these two components being mixed, otherwise the mixture would becometoo viscous to use. This requires the separate storage of differentcomponents, which increases the complexity of the manufacturing process.

Thus, there is a need for better materials and methods for manufacturingthree-dimensional objects using photopolymerizable 3D printingtechniques.

SUMMARY

Described herein are methods and materials to produce three-dimensionalobjects by additive manufacturing. In some embodiments, the materials toproduce the three-dimensional object comprises a polymerizable liquidcomprising:

(a) a blocked or reactively blocked polyurethane prepolymer;

(b) (optional) a reactive diluent;

(c) a blocked or reactively blocked curing agent;

(d) a photoinitiator; and

(e) (optional) a blocked or reactively blocked diisocyanate.

In some embodiments, the blocked or reactively blocked polyurethaneprepolymer comprises a polyisocyanate.

In some embodiments, the blocked or reactively blocked polyurethaneprepolymer has the structure of Formula (A):

wherein A and R are each independently a hydrocarbyl group, R′ is NH orO, and Z is a blocking group having a reactive epoxy, alkene, alkyne, orthiol terminal group.

In some embodiments, the blocking group Z is tert-butyl aminoethylmethacrylate (t-BAEMA).

In some embodiments, the blocked or reactively blocked curing agent ofthe polymerizable liquid has the structure of Formula (A1), Formula(A2), or Fomula (A3):

wherein R₁, R₂, and R₃ are each independently a linear or branchedC1-C36 alkyl or alkylene, alkenyl or alkenylene, aryl or arylene,heteroaryl or heteroarylene, cycloalkyl or cycloalkenyl moiety; Y₁ andY₂ are each independently a protecting group that protects amino groupsor hydroxyl groups.

In some embodiments, the protecting groups Y₁ and Y₂ have differentstructures.

In some embodiments, the blocked or reactively blocked curing agentcomprises an imine group, a substituent derived from reactions ofaldehydes or ketones with amines.

In some embodiments, the blocked or reactively blocked curing agentcomprises a carbamate group, a substituent derived from reactions ofcarboxylic acids or carboxylic esters with amines.

In some embodiments, the protecting groups Y₁ and/or Y₂ further comprisea photopolymerizable group.

In some embodiments, the photopolymerizable groups of Y₁ and/or Y₂comprise an acrylate or methacrylate group.

In some embodiments, the blocked or reactively blocked curing agent ofthe polymerizable liquid has the structure of Formula (A4), Formula(A5), or Formula (A6):

wherein R₄, R₅, and R₆ are each independently amino-dialkyl, a C3-C36aryl or arylene, cycloalkyl or cycloalkenyl moiety; Y₁ and Y₂ are eachindependently a protecting group that protects amino groups or hydroxylgroups; and X comprises a photopolymerizable group.

The present invention further provides a method of forming athree-dimensional object, comprising:

(a). providing a printing region defined by a forming platform and aresin reservoir having a forming surface;

(b). filling said printing region with a polymerizable liquid asdescribed elsewhere in the present disclosure;

(c). exposing said printing region to energy to form a solid printingintermediate having substantially the same shape as saidthree-dimensional object;

(d). (optional) washing said printing intermediate;

(e). heating, microwave irradiating, or using other methods to provideenergy to said printing intermediate to form said three-dimensionalobject.

In some embodiments, the blocked or reactively blocked curing agent usedthe method is contained in the printing intermediate in a cured orsolidified form.

In some embodiments, the formed three-dimensional object comprises apolymer blend, interpenetrating polymer network, semi-interpenetratingpolymer network, or sequential interpenetrating polymer network ofpolyurethane and polyacrylate.

In some embodiments, the formed three-dimensional object comprises acopolymer of polyurethane and polyacrylate.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the disclosure have other advantages and features whichwill be more readily apparent from the following detailed descriptionand the appended claims, when taken in conjunction with the examples inthe accompanying drawings, in which:

FIG. 1 is a schematic illustration of one embodiment of the Curingscheme A: Dual curing resin materials employing curing agents that donot participate in photopolymerization.

FIG. 2 is a schematic illustration of one embodiment of the CuringScheme B: Dual curing resin materials employing curing agents thatparticipate in photopolymerization.

FIG. 3 is a schematic illustration of one embodiment of the CuringScheme C: Dual curing resin materials employing curing agents thatcomprise asymmetrical protecting groups.

FIG. 4 is a schematic illustration of one embodiment of the CuringScheme D: Dual curing resin materials employing curing agent thatfurther comprises a crosslinking curing site.

DETAILED DESCRIPTION

The figures and the following description relate to preferredembodiments by way of illustration only. It should be noted that fromthe following discussion, alternative embodiments of the structures andmethods disclosed herein will be readily recognized as viablealternatives that may be employed without departing from the principlesof what is claimed.

“Diisocyanate” and “polyisocyanate” are used interchangeably and referto aliphatic, cycloaliphatic, aromatic isocyanates that have at least 2,or in some embodiments more than 2, isocyanate (NCO) groups permolecule, on average.

“Diol” and “polyol” are used interchangeably and refer to aliphatic,cycloaliphatic, aromatic alcohols that have at least 2, or in someembodiments more than 2 hydroxyl (OH) groups per molecule, on average.

As used herein, the term “and/or” refers to any and all possiblecombinations of one or more listed components, as well as any and allpossible of single component that lacks of any combination. For example,“A, B, and/or C” means all of the following possibilities: A alone, Balone, C alone, A and B, A and C, B and C, A, B and C.

As used herein, the term “visible light” refers to electromagneticradiation having wavelengths in the range of 400 to 700 nanometers (nm).“Ultraviolet light” as used here refers to electrometric radiationhaving wavelength in the range of 10 to 400 nanometers (nm).

As used herein, the term “stereolithography” or “photopolymerization”refers to a technique for making three-dimensional objects usinglight-initiated photopolymerization of liquid resin with the presence ofphotoinitiator.

As used herein, the term “curing”, “solidification” or “polymerization”refers to a process of reacting monomers, oligomers, prepolymers, and/orpolymers, with or without a curing agent to form a three-dimensionalpolymeric network.

Polymerizable liquids as described herein may be used in additivemanufacturing industry to produce three-dimensional objects. In someembodiments, the polymerizable liquid may comprise the followingcomponents:

(a) a blocked or reactively blocked polyurethane prepolymer;

(b) (optional) a reactive diluent;

(c) a blocked or reactively blocked curing agent;

(d) a photoinitiator; and

(e) (optional) a blocked or reactively blocked diisocyanate.

Polymerizable Liquid: Blocked or Reactively Blocked PolyurethanePrepolymer

In some embodiments, the blocked or reactively blocked polyurethaneprepolymers comprise a compound of the following formula (A):

where A and R are an independently selected hydrocarbyl group, R′ is NHor O, and Z is a blocking group. The linkage between the blocking groupZ and the isocyanate groups (—NCO) is thermally or otherwise labile sothat under proper conditions, such linkage may break to expose theisocyanate groups (—NCO), enabling the free isocynate to react withother components for further reaction. Examples of the NCO blockinggroup Z may include but not limited to phenols, nonyl phenols,pyridinols, oximes, thiophenols, mercaptans, amides, cyclic amides,imides, imidazole, imidazoline, methylethylketoxime (MEKO), alcohols,ε-caprolactam, pyrazoles, triazoles, amidines, hydroxaic acid ester.

In some embodiments, the NCO blocking group Z optionally comprises areactive terminal group, which makes the polyurethane prepolymerreactively blocked. Examples of the the reactive terminal group of Z mayinclude but not limited to epoxy, alkene, alkyne, thio, vinyl either. Inone embodiment, the blocking group Z is tert-butyl aminoethylmethacrylate (t-BAEMA) with the following formula:

In this example, the steric hindrance of the large tertiary butyl groupmakes the linkage between the blocking group and the isocyanate (—NCO)group thermally labile. Cleavage of this linkage may be expected uponheating, allowing the isocyanate (—NCO) group to react with curing agentand/or other components in the polymerizable liquids. In other examples,the blocking group Z may be tertiary penylaminoethyl methacrylate(TPAEMA), tertiary hexylaminoethyl methacrylate (THAEMA),tertiary-butylaminopropyl methacrylate (TBAPMA), and mixture thereof.Those skilled in the art may couple (meth)acrylate groups to known NCOblocking agents as identified above.

In some embodiments, the blocked or reactively blocked polyurethaneprepolymer comprises a polyisocyanate oligomer synthesized by thereaction of at least one diisocyanate and one polyol. Examples ofdiisocyante may include but not limited to isophorone diisocyanate(IPDI), hexamethylene diisocyanate (HDI), methylenebis(phenylisocyanate) (MDI), toluene diisocyanate (TDI), naphthalene diisocyanate(NDI), methylene bis-cyclohexylisocyanate (HMDI). Examples of polyolsmay include but not limited to polyether polyols and polyester polyols.One specific example of polyol is poly (propylene oxide) (PPO). Examplesof such reaction schemes were described in Velankar, Pazos, and Cooper,Journal of Applied Polymer Science 162, 1361 (1996), the disclosures ofwhich is incorporated by reference herein in their entirety.

Polymerizable Liquid: Reactive Diluent

In some embodiments, the reactive diluent may be photopolymerizablemonomer or oligomer having photopolymerizable groups. In someembodiments, the photopolymerizable groups may be groups that canundergo radical polymerization. In other embodiments, photopolymerizablegroups may be groups that can undergo cationic polymerization. In someembodiments, the photopolymerizable monomer or oligomer may comprise anacrylate, a methacrylate, an alkene, a N-vinyl, a vinyl amide, a vinylether, a vinyl ester, an acrylamide, a meth acrylamide, a styrene, anacrylate acid, an epoxy, a thio, a 1,3-dienes, a vinyl halide, anacrylonitrile, a vinyl ester, a maleimide, a vinyl ether, andcombination of two or more of the foregoing. In some embodiments, thephotopolymerizable monomer or oligomer may comprise epoxy/amine,epoxy/hydroxy, oxetane/amine, oxetane/hydroxy. Reactive diluents maydecrease the viscosity of the photopolymerized polymer network andcopolymerize with photopolymerizable components in the polymerizableliquid.

In some embodiments, the reactive diluent may have degree functionalityof one or more than one. Some examples of reactive diluent may includebut not limited to: 1,3-propanediol diacrylate and dimethacrylate,1,4-butanediol diacrylate and dimethacrylate, 1,5-pentanediol diacrylateand dimethacrylate, 1,6-hexanediol diacrylate and dimethacrylate,1,7-heptanediol diacrylate and dimethacrylate, 1,8-octanediol diacrylateand dimethacrylate, trimethylolpropanetriol triacrylate andtrimethacrylate, ethoxylated trimethylolpropanetriol triacrylate andtrimethacrylate, neopentyl glycol diacrylate and dimethacrylate,tripropylene glycol diacrylate and dimethacrylate, pentaerythritoltriacrylate and trimethacrylate, pentaerythritol tetraacrylate andtetramethacrylate, and the like. In some embodiments, certain reactivediluent or certain combination of reactive diluents are chosen in orderto increase the solubility of the photoinitiator used herein. Inpreferred embodiments, monomers with low degree of functionality areused to increase solubility of photoinitiators with the powder form.

Polymerizable Liquid: Photoinitiator

Photoinitiator may be any suitable photoinitiator that can initiate thephotopolymerization reaction with the light source used to initiate thephotopolymerization reaction. In some embodiments, the wavelength usedto initiate the photopolymerization process is 405 nm and in otherembodiments, the wavelength is 385 nm. Examples of photoinitiators mayinclude but not limited to benzoin ethers

dialkoxy acetophenones

hydroxy alkyl ketones

acyl phosphine oxides

amino ketones

benzophenones

thioxanthones

1,2 diketones

camphorquinone

bis(.eta.5-2,4-cylcopentadien-1-yl)-bis(2,6-difluoro-3-(1H-pyrrol-1-yl)-phenyl)titanium

where Rn is any number of other atoms, including H, O, C, N, S. In somepreferred embodiments, photoinitiators used herein are benzoyl phosphineoxides, including: TPO

Polymerizable Liquid: Blocked or Reactively Blocked Diisocyanate

In some embodiments, the polymerizable liquid may optionally compriseblocked or reactively blocked diisocyante. In some embodiments, theblocked or reactively blocked diisocyanate may comprise a compound ofthe following Formula:

where R is a hydrocarbyl group and Z is a blocking group. Examples ofthe blocking group Z may include but not limited to phenols, nonylphenols, pyridinols, oximes, thiophenols, mercaptans, amides, cyclicamides, imides, imidazole, imidazoline, Methylethylketoxime (MEKO),alcohols, ε-caprolactam, pyrazoles, triazoles, amidines, hydroxaic acidester. The linkage between the blocking group Z and the isocyanategroups (—NCO) is thermally or otherwise liable so that under properconditions, such linkage may break to exposed the isocyanate group,enabling the free isocyanate to react with other components for furtherreaction. In some embodiments, the blocking group Z optionally comprisesa reactive terminal group, which makes the diisocyanate reactivelyblocked. Examples of the the reactive terminal group of Z may includebut not limited to epoxy, alkene, alkyne, thio, vinyl either. In oneembodiment, the blocking Z is tert-butyl aminoethyl methacrylate(t-BAEMA) with the following structure:

In this example, the steric hindrance of the large teriary butyl groupmakes the linkage between the blocking group and the isocyanate (—NCO)group thermally labile. Cleavage of this bond may be expected uponheating, allowing the isocyanate (—NCO) group to react with curingagents in the polymerizable liquids. In other examples, the blockinggroup Z may be tertiary penylaminoethyl methacrylate (TPAEMA), tertiaryhexylaminoethyl methacrylate (THAEMA), tertiary-butylaminopropylmethacrylate (TBAPMA), and mixture thereof. Those skilled in the art maycouple (meth)acrylate groups to known NCO blocking agents as identifiedabove.

Polymerizable Liquid: Blocked or Reactively Blocked Curing Agent

In some embodiments, the blocked or reactively blocked curing agent maycomprise a compound of the following Formula (A1), Formula (A2), orFomula (A3):

wherein R₁, R₂, and R₃ are each independently a liner or branched C1-C36alkyl or alkylene, alkenyl or alkenylene, aryl or arylene, heteroaryl orheteroarylene, cycloalkyl or cycloalkenyl moiety and Y₁ and Y₂ are eachindependently selected protecting groups that protect amino groups orhydroxyl groups. In some embodiments, Y₁ and Y₂ are each independentlyselected and have different structures. In other embodiments, Y₁ and Y₂may have the same structures. Using curing agent with protecting groupsmay help increase the stability of the polymerizable liquid. In thisway, the different components may be mixed and stored without having thepolymerization reaction between the curing agent and the polyurethaneprepolymer occurred prematurely. The polymerization reaction between thecuring agent and the polyurethane prepolymer can be controlled to occuronly when the protecting groups are removed.

Examples of the amino group protecting group Y₁ and/or Y₂ may includebut not limited to an alkoxycarbonyl, an acyl group, an alkyl group, anda combination thereof. In some embodiments, the alkoxycarbonyl group maycomprise a benzyloxycarbonyl

a tert-butoxycarbonyl

a methoxycarbonyl

an allyloxycarbonyl

a trimethylsilyloxycarbonyl

a methoxycarbonyl or an ethoxycarbonyl

and a combination thereof. In some embodiments, the acyl group maycomprise phthalate

a p-toluenesulfonyl

a trifluoroacetyl

and a combination thereof. In some embodiments, the alkyl group maycomprise a tritylmethyl

a 2,4-dimethoxybenzyl

a p-methoxybenzyl

a benzyl

and a combination thereof. In some embodiments, the amino groupprotecting group Y₁ and/or Y₂ may also comprise 1-chloroethyl carbamate,4-methoxybenzenesulfonamide, acetamide, benzylamine, benzyloxycarbamate, formamide, methyl carbamate, trifluoroacetamide, and acombination thereof. More examples of the amino group protecting groupscan be found in Protective Groups in Organic Chemistry, J. McOmie,Springer Science & Business Media, declaration 2012.

Examples of the hydroxyl group protecting group Y₁ and/or Y₂ may includebut not limited to a silicon ether, a benzyl ether, a substituted benzylether, a substituted methyl ether, an alkoxymethyl ether, an allylether, an acyl ether and a combination thereof. In some embodiments, thesilicon ether may comprise a trimethylsilyl ether (TMS), at-Butyldimethylsilyl ether (TBDMS), a tert-butyldiphenylsilyl ether(TBDPS), a tri-isopropylsilyl ether (TIPS), and a combination thereof.In some embodiments, the benzyl ether (Bn) may comprise an alkyl hydroxybenzyl ether, a p-methoxybenzyl ether (PMB), a trityl ether, and acombination thereof. In some embodiments, the alkoxymethyl ether maycomprise a 2-tetrahydropyran ether (THP), a methoxymethyl acetal (MOM),a 2-ethoxyethyl ether (EE), 2-(Trimethylsilyl)ethoxy]methyl acetal (SEM)and a combination thereof. In some embodiments, the hydroxyl groupprotecting group Y₁ and/or Y₂ may comprise an acetyl, a benzoyl, apivaloyl, an acetate, a benzoate, a pivalate, and a combination thereof.In some embodiments, the hydroxyl group protecting group Y₁ and/or Y₂may also comprise 2,2,2,-trichloroethyl carbonate, 2-methoxyethoxymethylether, 2-naphthylmethyl ether, 4-methoxybenzyl ether, acetate, benzoate,benzyl ether, benzyloxymethyl acetal, ethoxyethyl acetal, methoxymethylacetal, methoxypropyl acetal, methyl ether, tetrahydropyranyl acetal,triethylsilyl ether, triisopropylsilyl ether, trimethylsilyl ether,tert-butyldiphenylsilyl ether, acetonide, benzaldehyde acetal,carbonate, benzaldehyde acetal, di-tert-butyl dioxasilinane, and acombination thereof. More examples of the hydroxyl group protectiongroups can be found in Protective Groups in Organic Chemistry, J.McOmie, Springer Science & Business Media, declaration 2012.

In some embodiments, when the curing agent is a protected amine or aprotected imine, the protecting group Y₁ and/or Y₂ may comprisecarboxylic acid groups, anhydride groups (an example of such anhydrideis di-tert-butyl decarbonate (Boc₂O), acid chloride groups (exampleswere described in U.S. Pat. Nos. 5,231,147, 3,639,657, 4,430,489, thedisclosure of which are incorporated herein by reference), aldehyde orketone groups (examples were described in U.S. Pat. No. 3,932,357, thedisclosure of which is incorporated herein by reference), complexes ofmetal salts (an example of such metal salt, methylenedianiline-NaCl wasdescribed in US Patent Application US 20070213497A1, the disclosure ofwhich is incorporated herein for reference).

In some embodiments, the protecting groups Y₁ and/or Y₂ in the curingagent may further comprise a photopolymerizable group. Examples of suchphotopolymerizable groups may include but not limited to an acrylate, amethacrylate, an alkene, a N-vinyl, an acrylamide, a methacrylamide, astyrene, an epoxy, a thio, a 1,3-dienes, a vinyl halide, anacrylonitrile, a vinyl ester, a maleimide, a vinyl ether, andcombination of two or more of the foregoing. In some embodiments, thephotopolymerizable group may comprise epoxy/amine, epoxy/hydroxy,oxetane/amine, oxetane/hydroxy. In some embodiments, Y₁ and Y₂ are eachindependently selected and have different structures. For example, oneof the protecting groups comprise a photopolymerizable terminal groupwhile the other does not.

In some embodiments, the protecting group Y₁ and/or Y₂ may comprise aphotopolymerizable (meth)acrylate group. In some embodiments, theprotecting groups Y₁ and/or Y₂ are each independently selected andhaving the same or different structures. Those skilled in the art maycouple (meth)acrylate groups or other photopolymerizable terminal groupsto known amino or hydroxyl group protecting groups as identified above.

In some embodiments, the protecting group Y₁ and/or Y₂ in itsunsubstituted form may comprise a compound of the following Formula:

(the O atom in the ketone group will be substituted when coupled toamino or hydroxyl groups to protect them), wherein Ry may be:

(1). linear or branched hydrocarbyl groups. In some embodiments, thenumber of carbon atoms in the hydrocarbyl groups may be in the range of1-10. In one example, the protecting group Y₁ and/or Y₂ in itsunsubstituted form may have the molecular structure as the following:

in another example, the protecting groups Y₁ and/or Y₂ in itsunsubstituted form may have the molecular structure as the following:

wherein n may be an integer in the range of 1-10;

(2). repeating units comprising alkoxy group. In some embodiments, thenumber of the repeating units may be in the range of 1-10. In oneexample the protecting groups Y₁ and/or Y₂ in its unsubstituted form mayhave the molecular structure as the following:

wherein n may be an integer in the range of 1-10 and R is a linear orbranched hydrocarbyl group;

(3). repeating units comprising ester group;

(4). repeating units comprising siloxy group; or

(5). repeating units comprising thioether group.

Some examples of the preparation of the protecting groups Y₁ and/or Y₂described above is shown in the Schemes below:

wherein CAT is a phase transfer catalyst. Examples of such phasetransfer catalyst that can be used here may comprise amine salts (suchas benzyltriethylammonium chloride (TEBA) or ammonium bromide (TEBA-Br),benzyltrimethylammonium chloride, ammonium bromide or ammonium hydroxide(Triton B), tetrabutyl chloride Ammonium bromide, ammonium iodide orammonium hydroxide, cetyltrimethylammonium bromide, ammonium chloride,tetra-n-hexylammonium bromide, ammonium chloride, etc.), crown ethers(such as 15-crown-5, 18-crown-6, dibenzo-18-crown-6, etc.), phosphoniumsalts (such as tributylphosphonium bromide, ethyltriphenylphosphoniumbromide, tetraphenylphosphonium chloride, etc.) In some embodiments, thephase transfer catalyst may be used together with agents such asdicyclohexylcarbodiimide (DCC) to promote the esterification reaction.

In some embodiments, the protecting groups Y₁ and/or Y₂ in itsunsubstituted form may be methyl isobutyl ketone (MIBK), where the Oatom in the ketone group will be substituted when coupled to the aminoor hydroxyl groups to protect them.

In some embodiments, the blocked or reactively blocked curing agent maycomprise a compound of the following Formula (A4), Formula (A5), orFomula (A6):

wherein R₄, R₅, and R₆ are each independently an amino-dialkyl, anC6-C36 aryl or arylene, a C6-C36 heteroaryl or heteroarylene, C3-C36cycloalkyl or cycloalkenyl moiety, X comprises a photopolymerizablegroup, and Y₁ and Y₂ are each independently selected protecting groupsthat protect amino groups or hydroxyl groups. In some embodiments, Y₁and Y₂ are each independently selected and have different structures. Inother embodiments, Y₁ and Y₂ may have the same structures. In theseembodiments, the curing agent comprises a crosslinking curing site, X,that enables the curing agent to crosslink the thermoplasticpolyurethane segments with UV-cured crosslinked acrylate part in thedual curing process to form an acrylic-urethane copolymer network.Compared to the acrylate-urethane system that crosslinked acrylate andurethane are not copolymerized, such copolymer network not onlymaintains the high elongation and elastic properties, it also makes thenetwork stronger and more endurable. In some embodiments, R₄, R₅, and R₆may have more than three substituted sites.

In some embodiments, the curing agent may have the molecular structureas the following:

which is an example of Formula A₅ with R₅ being a diethylamino group, Xbeing a 2-hydroxypropyl methacrylate and Y₁ and Y₂ being a methylisobutyl ketone (MIBK) group (with the oxygen atom in the ketone groupsubstituted when reacting with amine). In this example, the curing agentmay be synthesized with the following reaction scheme:

In addition to diethylenetriamine (DETA) used to synthesize the abovecuring agent, those skilled in the art may use other type of aminecompounds to prepare the curing agent having a crosslinking curing site.Examples may include but not limited to triethylenetetramine (TETA) andN-(4-Aminocyclohexyl)-1,4-cyclohexanediamine.

Some embodiments of the present invention disclosed a method of forminga three-dimensional object using the polymerizable liquids describedherein. The method may comprise the following steps:

(1). providing a printing region defined by a forming platform and aresin reservoir having a forming surface;

(2). filling the printing region with a polymerizable liquid comprising:

-   -   a) a blocked or reactively blocked polyurethane prepolymer;    -   b) (optional) a reactive diluent;    -   c) a blocked or reactively blocked curing agent;    -   d) a photoinitiator; and    -   e) (optional) a blocked or reactively blocked diisocyanate;

(3). exposing the printing region to light to form a solid printingintermediate having substantially the same shape as thethree-dimensional object; in some embodiments, the blocked or reactivelyblocked curing agent is contained in the printing intermediate in auncured or unsolidified form; in other embodiments, the blocked orreactively blocked curing agent may participate in thephotopolymerization process when exposed to light through itsphotopolymerizable terminal groups and as a result, is contained in theprinting intermediate in a cured or solidified form.

(4). (optional) washing the printing intermediate;

(5). heating, microwave irradiating, exposing to water vapor or usingother methods to provide energy to the printing intermediate to form thethree-dimensional object through a second step of curing; under heating,microwave irradiating, moisturizing conditions or other knownconditions, the blocking groups in the polyurethane prepolymer and theprotecting groups in the curing agent will undergo cleavage, which meansthat the linkage between the blocking/protecting groups and theblocked/protected parts will be cleaved so that the blocked/protectedparts can be exposed for further curing. Depending on the variousdesigns of the curing agent described herein, there may be differentcuring schemes for the present invention. Non-limiting examples of suchcuring schemes are described further below.

A. Dual Curing Resin Materials Employing Curing Agents that do notParticipate in Photopolymerization Reaction

In these embodiments, the protecting groups Y₁ and Y₂ are eachindependently selected protecting groups that protect amino groups orhydroxyl groups but do not comprise photopolymerizable groups. In theseembodiments, when the polymerizable liquid comprising such curing agentis exposed to light to form a solid printing intermediate, the printingintermediate contains the curing agent in its uncured or unsolidifiedform. Following the photopolymerization, under heating, microwaveirradiating, moisturizing conditions, or other known suitableconditions, the protecting groups Y₁ and Y₂ are cleaved and expose theoriginally protected amino or hydroxyl groups for further curing. Anexample of such curing scheme is illustrated in FIG. 1.

In the example illustrated in FIG. 1, the polyurethane prepolymerterminated with ethylenically unsaturated blocking groups undergoesphotopolymerization reaction (optionally) together with the reactivediluent to form a crosslinked network (i.e., a solid printingintermediate) containing the protected curing agent in its uncured form.In the reaction scheme illustrated in FIG. 1, the curing agent is adiamine compound. After the photopolymerization, under heating,microwave irradiating, moisturizing conditions or other known suitableconditions, the blocking groups that block the isocyante groups arecleaved and expose them for further curing. Also under the samecondition, the protecting groups in the curing agent that protect theamino groups are also cleaved and expose the amino groups to react withisocyante groups to form a network that comprises the following: (a)linear thermoplastic polyurethane, polyurea, and/or copolymer thereof;(b) crosslinked thermoset polyurethane, polyurea, and/or copolymerthereof; (c) UV-cured polyacrylates (linear or crosslinked); and (d)combinations thereof. Such network may be an interpenetrating polymernetwork (IPN), a semi- or pseudo-IPN, a sequential IPN. However, inthese embodiments, the polyurethane part of network and polyacrylatespart of network are not covalently bonded. In some embodiments, thenetwork also comprises other components, for example, the copolymer ofthe de-protected curing agent and the reactive diluent, and unreactedphotoinitiator, etc.

B. Dual Curing Resin Materials Employing Curing Agents that Participatein Photopolymerization

In these embodiments, the protecting groups Y₁ and Y₂ are independentlyselected protecting groups that protect amino groups or hydroxyl groupsand further comprise photopolymerizable groups. In these embodiments,when the polymerizable liquid comprising such curing agent is exposed tolight to form a solid printing intermediate, the printing intermediatecontains the curing agent in a cured or solidified form. An example ofsuch curing scheme is illustrated in FIG. 2.

In the example illustrated in FIG. 2, the polyurethane prepolymerterminated with ethylenically unsaturated protected groups undergoesphotopolymerization reaction together with also ethylenicallyunsaturated protected curing agent and (optionally) reactive diluentunder photo irradiation to form a crosslinked network (i.e., a solidprinting intermediate) containing the protected curing agent in itscured or solidified form. In the reaction scheme illustrated in FIG. 2,the curing agent is a diamine compound, protected on both ends withphotopolymerizable protecting groups. Because in these embodiments, thecuring agent is contained in the printing intermediate in its cured orsolidified form, as a result, the printing intermediate may havestronger mechanical strength and be easier for the post-processinghandling. After the photopolymerization, under heating, microwaveirradiating, moisturizing conditions or other known suitable conditions,the blocking groups that block the isocyanate groups are cleaved andexpose them for further curing. Also under the same condition, theprotecting groups in the curing agent that protect the amino group arealso cleaved and expose the amino groups to react with isocyanate groupsto form a network that comprise the following: (a) linear thermoplasticpolyurethane, polyurea, and/or copolymer thereof; (b) crosslinkedthermoset polyurethane, polyurea, and/or copolymer thereof; (c) UV-curedpolyacrylates (linear or crosslinked); and (d) combinations thereof.Such network may be an interpenetrating polymer network (IPN), a semi-or pseudo-IPN, a sequential IPN. However, in these embodiments, thepolyurethane part of network and polyacrylates part of network are notcovalently bonded. In some embodiments, the network also comprises othercomponents, for example, the copolymer of the de-protected curing agentand the reactive diluent, and unreacted photoinitiator, etc.

C. Dual Curing Resin Materials Employing Curing Agent that ComprisesAsymmetrical Protecting Groups

In these embodiments, the protecting groups Y₁ and Y₂ are independentlyselected protecting groups that protect amino groups or hydroxyl groupsand have different chemical structures. In some examples, one of the twoprotections groups comprise photopolymerizable terminal group and theother does not. In these embodiments, when the polymerizable liquidcomprising such curing agent is exposed to light to form a solidprinting intermediate, the printing intermediate contains the curingagent in a cured or solidified form. An example of such curing scheme isillustrated in FIG. 3.

In the example illustrated in FIG. 3, the polyurethane prepolymerterminated with ethylenically unsaturated blocking groups undergoesphotopolymerization reaction together with also ethylenicallyunsaturated protected curing agent only on one end and (optionally)reactive diluent under photo irradiation to form a crosslinked network(i.e., a solid printing intermediate) containing the protected curingagent in its cured form. In the reaction scheme illustrated in FIG. 3,the curing agent is a diamine compound, protected only on one end withone photopolymerizable protecting group. Because in these embodiments,the curing agent is contained in the printing intermediate in its curedform, as a result, the printing intermediate may have strongermechanical strength and be easier for the post-processing handling.After the photopolymerization, under heating, microwave irradiating,moisturizing conditions or other known suitable conditions, the blockinggroups that block the isocyante groups are cleaved and expose them forfurther curing. Also under the same condition, the protecting groups inthe curing agent that protect the amino group are also cleaved andexpose the amino groups to react with isocyante groups to form a networkthat comprise the following: (a) linear thermoplastic polyurethane,polyurea, and/or copolymer thereof; (b) crosslinked thermosetpolyurethane, polyurea, and/or copolymer thereof; (c) UV-curedpolyacrylates (linear or crosslinked); and (d) combinations thereof.Such network may be an interpenetrating polymer network (IPN), a semi-or pseudo-IPN, a sequential IPN. However, in these embodiments, thepolyurethane part of network and polyacrylates part of network are notcovalently bonded. Compared to the above Curing Scheme B, this curingscheme C offers another option that allows one to adjust the compositionof the final three-dimensional network in order to adjust the physicalproperties of the three-dimensional printed objects. In someembodiments, the network also comprises other components, for example,the copolymer of the de-protected curing agent and the reactive diluent,and unreacted photoinitiator, etc.

D. Dual Curing Resin Materials Employing Curing Agent that Comprises aCrosslinking Curing Site

In these embodiments, the protecting groups Y₁ and Y₂ are eachindependently selected protecting groups that protect amino groups orhydroxyl groups but do not participate in the photopolymerizationreaction. The curing agent further comprises a crosslinking curing site,X, that enables the curing agent crosslinking the thermoplasticpolyurethane segments with UV-cured crosslinked polyacrylate part in thedual curing process to form an acrylic-urethane copolymer. In theseembodiments, when the polymerizable liquid comprising such curing agentis exposed to light to form a solid printing intermediate, the printingintermediate contains the curing agent in a cured or solidified form. Anexample of such curing scheme is illustrated in FIG. 4.

In the example illustrated in FIG. 4, the polyurethane prepolymerterminated with ethylenically unsaturated blocking groups undergoesphotopolymerization reaction together with also ethylenicallyunsaturated protected curing agent on a crosslinking curing site and(optionally) reactive diluent under photo irradiation to form acrosslinked network (i.e., a solid printing intermediate) containing thecuring agent in its cured form. In addition to the crosslinking curingsite that enables the curing agent to participate in thephotopolymerization, the curing agent also has one or more protectedamino or hydroxyl groups that once deprotected, enables the reactionbetween the deblocked polyurethane prepolymer and the deprotected curingagent to form polyurethane. In the reaction scheme illustrated in FIG.4, the curing agent is a diamine compound with two amino groupsprotected and one ethylenically unsaturated crosslinking curing site.Because in these examples, the curing agent is contained in the printingintermediate in its cured form, as a result, the printing intermediatemay have stronger mechanical strength and be easier for thepost-processing handling. After the photopolymerization, under heating,microwave irradiating, moisturizing conditions or other known suitableconditions, the blocking groups that block the isocyante group arecleaved and expose it for thermal curing. Also under the same condition,the protecting groups in the curing agent that protect the amino groupsare also cleaved and expose the amino groups to react with isocyanategroups to form a network that comprise the following: (a) linearthermoplastic polyurethane, polyurea, and/or copolymer thereof; (b)crosslinked thermoset polyurethane, polyurea, and/or copolymer thereof;(c) UV-cured polyacrylates (linear or crosslinked); (d) copolymer ofpolyurethane, polyurea, and/or copolymer thereof and UV-curedpolyacrylates; and (e) combinations thereof. Compared to previous curingschemes, this curing scheme covalently bonded the polyurethane part ofthe network and polyacrylates part of the network in thethree-dimensional network. As a result, the formed three-dimensionalprinted object does not only maintain the good elongation property, butalso offers better strength and durability. In some embodiments, thenetwork also comprises other components, for example, the copolymer ofthe de-protected curing agent and the reactive diluent, and unreactedphotoinitiator, etc.

Embodiments of the polymerizable liquids disclosed in the presentinvention can be used to manufacture three-dimensional objects usingcommonly known photopolymerization 3D printing technologies, such asstereolithography (SLA), Digital Light Processing (DLP), and MaterialJetting (MJ). In some embodiments, an additive manufacturing method toproduce three-dimensional objects using the polymerizable liquids of thepresent invention comprises the following steps:

(a). providing a printing region defined by a forming platform and aresin reservoir having a forming surface;

(b). filling said printing region with the polymerizable liquiddisclosed in the present invention;

(c). exposing the printing region to energy to form a solid printingintermediate having substantially the same shape as thethree-dimensional object;

(d). (optional) washing said printing intermediate;

(e). heating, microwave irradiating, or using other methods to provideenergy to said printing intermediate to form said three-dimensionalobject.

In some embodiments, in the method described herein, the polymerizableliquid comprise from 1 percent by weight to 99 percent by weight theblocked or reactively blocked polyurethane prepolymer; and from 1percent by weight to 99 percent by weight the blocked or reactivelyblocked curing agent.

In some embodiments, the solid printing intermediate is firstmanufactured by a DLP printer through the first curing step ofphotopolymerization. In some embodiments, the wavelength used toinitiate the photopolymerization process is 405 nm and in otherembodiments, the wavelength is 385 nm. Any suitable photoinitiator thatcan initiate the photopolymerization reaction with the light source usedherein may be used. In some preferred embodiments, light with thewavelength longer than 400 nm is used to initiate thephotopolymerization. In particular, 405 nm wavelength is used. In thesepreferred embodiments, photoinitiator Irgacure 819 is used for lightwith wavelength longer than 400 nm because 819 has a strong absorptionin the family of phosphine oxide type of photoinitiator in the longwavelength UV range.

After the printing intermediate is formed, it is optionally washed anddried. In some embodiments, the washing liquid may be aqueous andcomprise water and surfactant. In some embodiments, the water can bedeionized water. Examples of surfactant may include but not limited toanionic surfactants (e.g., sulfates, sulfonates, carboxylates, andphosphate esters), cationic surfactants, zwitterionic surfactants,nonionic surfactants, etc., including combinations thereof. Commonexamples include, but are not limited to, sodium stearate, linearalkylbenzenesulfonates, lignin sulfonates, fatty alcohol ethoxylates,alkylphenol ethoxylates, etc., including combinations thereof.

After the optional washing step, the printing intermediate is furthercured to form the final printed three-dimensional object. The secondstep of curing may be carried out by heat, moisturization, microwaveirradiation, or other suitable energy source that can cleave theblocking/protecting groups used in the polymerizable liquid resins inorder to initiate the second curing process. In some embodiments, thesecond step of curing is heating curing. In some embodiments, thetemperature of the heat curing may be in the range of ambienttemperature ˜200° C. The length of the heat curing time may be in therange of 0.5h˜200h. In some embodiments, the second step of curing isheating under moisturizing condition.

Embodiments of the present invention are explained in detail in thefollowing non-limiting examples:

Example 1 Synthesis of Reactively Blocked Polyurethane Prepolymer

200 grams anhydrous polybutylene glycol (PTMG 1000) is added into 500-mlthree-necked flask with an overhead stir, a thermometer and nitrogenprotection. 67.2 grams hexamethylene diisocyanate (HDI) is then addedinto the flask to form a homogeneous solution with PTMG with 10-min'sstirring, followed by addition of 140 μl of dibutyltindilaurate (DBTL)catalyst at 70° C. for 3 hours. After 3 hours, 75 grams oftertiary-butylaminoethyl methacrylate (TBAEMA) is gradually added. Thetemperature is then set at 50° C. with the addition of 100 ppm ofbenzene-1,4-diol. The reaction continues for 10 hours to produce ProductA in a clear liquid form. The reaction scheme is illustrated in thefollowing:

Example 2 Synthesis of the Reactively Blocked Diisocyanate

88.9 grams of isophorone diisocyanate (IPDI) is added into 500-mlthree-necked flask with an overhead stir, a thermometer and nitrogenprotection with 140 μl of DBTL catalyst and 75 grams of TBAEMA and 100ppm of benzene-1,4-diol. The reaction continues for 3 hours at 70° C. toproduce product B in a clear liquid form. The reaction scheme isillustrated in the following:

Example 3 One-Pot Synthesis of Reactively Blocked PolyurethanePrepolymer and Reactively Blocked Diisocyanate

200 grams anhydrous polybutylene glycol (PTMG 1000) is added into 500-mlthree-necked flask with an overhead stir, a thermometer and nitrogenprotection. 134.4 grams hexamethylene diisocyanate (HDI) is then addedinto the flask to form a homogeneous solution with PTMG with 10-min'sstirring, followed by addition of 240 μl of dibutyltindilaurate (DBTL)catalyst at 70° C. for 3 hours. After 3 hours, 255 grams oftertiary-butylaminoethyl methacrylate (TBAEMA) is gradually added. Thetemperature is then set at 50° C. with the addition of 100 ppm ofbenzene-1,4-diol. The reaction continues for 10 hours to produce productC in a clear liquid form, which is mixture of reactively blockedpolyurethane prepolymer and the reactively blocked diisocyanate.

Example 4 Synthesis of Polyamine Protected with Carboxylic Acid

504.6 grams of 2-methylpentamethylenediamine is mixed with 295.4 gramsof sebacic acid under nitrogen protection. The mixture is then heated to245° C. gradually with the reaction temperature kept above 230° C. forabout 10 hours. After evacuation to remove traces of moisture, themolten Product D is discharged and cooled under the nitrogen protectionin a desiccator. Once cooled and solidified completely, the productresin is broken into pieces in medium size and then grounded into powderusing a centrifugal pulverizer. After being sifted through a 250μ screento remove coarse particles, the powder resin is then packaged undernitrogen protection for future use.

Example 5 DLP 3D Printing Test Using the Products from Examples 1, 2 and4

At room temperature, polyethylene glycol (600) methacrylate,1,4-butanediol diacrylate and photoinitiator TPO are mixed using a rotormixer for 30 minutes at 500 rpm to obtain a clear liquid. Product A, Band D from Examples 1, 2 and 4, respectively are mixed into this clearliquid using the rotor mixer for 40 minutes at 1500 rpm until anotherclear liquid is obtained. Blue coloring agent is then added to this newclear liquid and mixed using the rotor mixer for 30 minutes at 2000 rpmto yield printing material for 3D printing. The viscosity of theprinting material is tested as 4400 cps at the production and thenbecomes 4500 cps after storage at room temperature for 3 months. Theviscosity only has a 2% increase over three months, demonstrating goodstability. The specific amount of each reactants to produce the finalprinting material is listed in the following table. A test strip isobtained from the above-mentioned printing material using a From 1+ SLAprinter with a laser power of 5 mW and a scan rate of 3 m/s. The teststrip is then placed in an oven at 140° C. for 10 hours to completethermal curing. A tensile test in accordance with the ASTM D412 standardshows a 36.7±1.3 MPa tensile strength and a 352±25% of elongation break.

Weight Percentage Component (wt %) Product A from Example 1 45 Product Bfrom Example 2 15 polyethylene glycol 20 (600) methacrylate1,4-butanediol diacrylate 9 Product D from Example 4 10 photoinitiatorTPO 0.5 Blue coloring agent 0.5

Example 6 Synthesis of MIBK Protected Curing Agent DMDC

3,3-Dimethyl-4,4-diaminodicyclohexylmethane (DMDC) and methyl isobutylketone (MIBK) in an excess amount (molar ratio of 1:4) are placed in areactor and stirred at an elevated temperature in an oil bath. Thereaction temperature is first raised to 130° C. in order to form areflux reaction. After 2 hours of reaction at 130° C., the refluxreaction continues for about 4 hours at 150-160° C. After the completionof the reaction, the product mixture is purified by vacuum distillationat 120° C. for 2-3 hours in order to remove product water and excessmethyl isobutyl ketone to obtain a pale, yellow and transparent liquid Ewith a yield ratio of about 95%. The reaction scheme is illustrated inthe following:

Example 7 DLP 3D Printing Test Using the Products from Examples 3 and 6

A solution is obtained by dissolving photoinitiator TPO into1,6-hexanediol dimethacrylate and polyethylene glycol (600)dimethacrylate (PEG(600) DMA). Product C from Example 3 andMIBK-protected ketoimine curing agent from Example 6 are added into theabove solution and mixed together to obtain a uniform printing material.A dog-bone shaped test strip is then prepared from the above-mentionedprinting material using LEAP™ printing technology. After the printing,the test strip is first cleaned and then left for 12 hours in anenvironment of 25° C. and 65% humidity. The test strip is then placed inan oven at 120° C. for 8 hours to complete thermal curing. A mechanicalproperty test is conducted using a CTM tensile machine. A tensile testin accordance with the ASTM D412 standard shows a 20 MPa tensilestrength and a 310% of elongation break.

Parts by Component Weight Product C from Example 3 70 PEG(600)DMA 101,6-hexanediol dimethacrylate 20 Product E from Example 6 11.15 TPO 1.0

Example 8 Synthesis of Boc₂O Protected Curing Agent PACM

120 grams of water and 9.14 g (0.0435 mol) of 4,4-diaminodicycyclohexylmethane (PACM) are added into a 205 ml one-neck flask and stirred for 20minutes. 20.9 grams (0.0957 mol) of di-tert-butyl decarbonate (Boc2O) isthen added to react at room temperature (30-35° C.). In the beginning ofthe reaction, the reactants in the flask first turn into a whiteemulsion and a small amount of bubbles appear on the inner wall of theflask. After 3 hours of reaction a large amount of white precipitateappears, indicating that the reaction is almost complete. The reactionproduct is then filtered using a reduced-pressure funnel to remove theaqueous phase. The filtered solid phase is washed three times with 200ml of distilled water and then filtered to obtain white and solidmaterial. This material is dried under vacuum at 90° C. for 4 h to yielda white powdery solid Product F with a yield ratio of about 50%. Thereaction scheme is illustrated in the following:

Example 9 DLP 3D Printing Test Using the Products from Example 3 andExample 8

A solution is obtained by dissolving photoinitiator TPO into laurylmethacrylate (LMA) and polyethylene glycol (600) dimethacrylate(PEG(600) DMA). Product C from Example 3 and Boc20-protected curingagent from Example 8 are added into the above solution and mixed toobtain a uniform printing material. A dog-bone shaped test strip is thenprepared from the above-mentioned printing material using LEAP™ printingtechnology. After the printing, the test strip is first cleaned and thenplaced in an oven at 120° C. for 8 hours to complete thermal curing. Amechanical property test in accordance with the ASTM D412 standard isconducted using a CTM tensile machine. The specific amount of eachreactants to produce the final printing material are listed in thefollowing tables. A tensile test in accordance with the ASTM D412standard shows a 18 MPa tensile strength and a 280% of elongation break.

Parts by Component Weight Product C from Example 3 75 PEG(600)DMA 10 LMA15 Product F from Example 8 12.19 TPO 0.8

Example 10 DLP 3D Printing Test Using Products from Example 3 andMethylenedianiline⋅NaCl Curing Agent

At room temperature, polyethylene glycol (600) acrylate, 2-ethylhexylacrylate, methylenedianiline-NaCl and photoinitiator TPO-L are mixedusing a rotor mixer for 30 minutes at 500 rpm to obtain a clear liquid.Product C from Examples 3 is mixed into this clear liquid and using therotor mixer for 40 minutes at 1500 rpm until another clear liquid isobtained. Red coloring agent is then added to this new clear liquid andmixed using the rotor mixer for 30 minutes at 2000 rpm to yield printingmaterial for 3D printing. The viscosity of the printing material istested as 3400 cps and then becomes 3700 cps after storage at roomtemperature for 3 months, which is only a 8% increase, demonstratinggood stability. The specific amount of each reactants to produce thefinal printing material is listed in the following table. A test stripis obtained from the above-mentioned printing material using a From 1+SLA printer with a laser power of 3.5 mW and a scan rate of 3.5 m/s. Thetest strip is then placed in an oven at 140° C. for 10 hours to completethermal curing. A tensile test in accordance with the ASTM D412 standardshows a 25.3±2.7 MPa tensile strength and a 452±15% of elongation break.

Weight Percentage Component (wt %) Product C from Example 3 70polyethylene glycol (600) acrylate 20 2-ethylhexyl acrylate 4methylenedianiline•NaCl 5 Photoinitiator TPO-L 0.7 Red coloring agent0.3

Example 11 Synthesis of Photopolymerizable Ketone Protected Curing Agent

3,3-Dimethyl-4,4-diaminodicyclohexylmethane (DMDC) and3,3-dimethyl-4-oxopentyl methacrylate in an excess amount (molar ratioof 1:2) is placed in a reactor and stirred at an elevated temperature inan oil bath. The reflux reaction continues for about 8 hours at 150-160°C. After the completion of the reaction, the product mixture is purifiedby vacuum distillation at 120° C. for 2-3 hours in order to removeproduct water and excess 3,3-dimethyl-4-oxopentyl methacrylate to obtaina pale, yellow and transparent liquid H with a yield ratio of about 85%.The reaction scheme is illustrated in the following:

Example 12 DLP 3D Printing Test Using Products from Example 3 andExample 11

At room temperature, polyethylene glycol (600) methacrylate,1,6-hexanediol diacrylate and photoinitiator 819 are mixed using a rotormixer for 30 minutes at 500 rpm to obtain a clear liquid. Product C andF from Examples 3 and 11, respectively are mixed into this clear liquidusing the rotor mixer for 40 minutes at 1500 rpm until a clear liquidprinting material for 3D printing is ready. The viscosity of theprinting material is tested as 3500 cps at the production and thenbecomes 3800 cps after storage at room temperature for 3 months. Theviscosity only has a 8% increase over three months, demonstrating goodstability. The specific amount of each reactants to produce the finalprinting material is listed in the following table. A test strip isobtained from the above-mentioned printing material using a From 1+ SLAprinter with a laser power of 8 mW and a scan rate of 2.5 m/s. The teststrip is then placed in an oven at 120° C. for 15 hours to completethermal curing. A tensile test in accordance with the ASTM D412 standardshows a 22.2±3.3 MPa tensile strength and a 283±12% of elongation break.

Weight Percentage Component (wt %) Product C from Example 3 63.6 ProductH from Example 11 15.4 polyethylene glycol 12 (600) methacrylate1,6-hexanediol diacrylate 8 photoinitiator 819 1.0

Example 13 Synthesis of Photopolymerizable Boc20 Protected Curing AgentPACM

120 grams of water and 9.14 g (0.0435 mol) of 4,4-diaminodicycyclohexylmethane (PACM) is added into a flask and stirred for 20 minutes. 30.5grams ((oxybis(carbonyl))bis(oxy))bis(2-methylpropane-2,1-diyl)bis(2-methylacrylate) is then added to react at room temperature (30-35°C.). In the beginning of the reaction, the reactants in the flask firstturns into a white emulsion and a small amount of bubbles appear on theinner wall of the flask. After 5 hours of reaction a large amount ofwhite precipitate appears, indicating that the reaction is almostcomplete. The reaction product is then filtered using a reduced-pressurefunnel to remove the aqueous phase. The filtered solid phase is washedthree times with 200 ml of distilled water and filtered to obtain whiteand solid material. This material is dried under vacuum at 90° C. for 4h to yield a white powdery solid product G with a yield ratio of about60%. The reaction scheme is illustrated in the following:

Example 14 DLP 3D Printing Test Using Products from Example 1 andExample 13

At room temperature, isobornyl methacrylate, 2-ethylhexyl acrylate,Product G from Example 13 and photoinitiator TPO are mixed using a rotormixer for 30 minutes at 500 rpm to obtain a clear liquid. Product A fromExample 1 is then mixed into this clear liquid using the rotor mixer for30 minutes at 2000 rpm until a clear liquid printing material for 3Dprinting is ready. The viscosity of the printing material is tested as2200 cps at the production and then becomes 2400 cps after storage atroom temperature for 3 months. The viscosity only has a 9% increase overthree months, demonstrating good stability. The specific amount of eachreactants to produce the final printing material is listed in thefollowing table. A test strip is obtained from the above-mentionedprinting material using a From 1+ SLA printer with a laser power of 3.5mW and a scan rate of 3.5 m/s. The test strip is then placed in an ovenat 140° C. for 10 hours to complete thermal curing. A tensile test inaccordance with the ASTM D412 standard shows a 55.3±2.7 MPa tensilestrength and a 102±11% of elongation break.

Weight Percentage Component (wt %) Product A from Example 1 50 Product Gfrom Example 13 16.2 isobornyl methacrylate 20 2-ethylhexyl acrylate13.1 photoinitiator TPO 0.7

Example 15 Synthesis of 2-Methyl, 4-Oxopentyl Ester-Blocked DMDC

3,3-Dimethyl-4,4-diaminodicyclohexylmethane (DMDC) and 2-methyl,4-oxopentyl ester in an excess amount (molar ratio of 1:2) is placed ina reactor and stirred at an elevated temperature in an oil bath. Thereflux reaction continues for about 8 hours at 150-160° C. After thecompletion of the reaction, the product mixture is purified by vacuumdistillation at 120° C. for 2-3 hours in order to remove product waterand excess 2-methyl, 4-oxopentyl ester to obtain a pale, yellow andtransparent liquid I with a yield ratio of about 85%. The reactionscheme is illustrated in the following:

Example 16 DLP 3D Printing Test Using the Products from Example 15

A solution is obtained by dissolving photoinitiator TPO, lightstabilizer 292, antioxidant 1135 into lauryl methacrylate (LMA) andpolyethylene glycol (600) dimethacrylate (PEG(600) DMA) using Thinky™mixer. TBAEMA-blocked polyurethane prepolymer(TBAEMA-IPDI-PTMO2000-IPDI-TBAEMA and Product I from Example 15 areadded into the above solution and mixed together to obtain a uniformprinting material using Thinky™ mixer. A dog-bone shaped test strip isthen prepared from the above-mentioned printing material using LEAP™printing technology. After the printing, the test strip is first cleanedand then placed in water at 60° C. for 30 min, and then in an oven at120° C. for 8 hours to complete thermal curing. A mechanical propertytest in accordance with the ASTM D412 standard is conducted using a CTMtensile machine. The specific amount of each reactants to produce thefinal printing material and the tested mechanical properties are listedin the following tables:

Parts by Weight Test sample #1 Test sample #2 Test sample #3TBAEMA-IPDI- 70 70 70 PTMO2000- IPDI-TBAEMA PEG(600)DMA 25 10 15 LMA 520 15 Product I from 15 20 15 Example 15 TPO 0.5 0.5 0.5 1135 1 1 1 2920.7 0.7 0.7 Mechanical Property Tensile Strength (MPa) 22 20 16Elongation Break (%) 240 270 260

Example 17 Synthesis of a Protecting Ketone to Protect Polyamine

In a three-necked flask equipped with a stirrer, a condenser and athermometer, 1 mol of methacrylate polymerization inhibitor (0.1%-0.3%by mass), 3-6 mol of solvent, and a ketone containing chlorine group,such as,

where n=3, are added, stirred well and heated to react. The reactiontemperature is controlled between 80-120° C. After 4-8 hours, when thereaction is completed, NaCl is filtered to obtain filtrate. Then thefiltrate is distilled under reduced pressure at 30-60° C. to distill offany unreacted materials and solvents and then rectified at 80-130° C. toobtain a colorless and transparent product. In this example, themethacrylate polymerization inhibitor may be hindered phenols, aromaticamines, or quinones, etc. The solvent may be benzene (such as benzene,toluene, etc.), alkanes (such as cyclohexane, n-heptane, petroleumether, etc.) The phase transfer catalyst may be benzyltriethylammoniumchloride (TEBA).

Example 18 Synthesis of Another Protecting Ketone to Protect Polyamine

1.1-3.5 mol of alcohol containing carbonyl group, such as

where n=3, 1 mol of methacrylic acid, 8-10 mol of dichloromethane as thesolvent, 0.03-0.1 mol of DMAP (4-dimethylaminopyridine) as the phasetransfer catalyst are added into the reactor and stirred well.Temperature is reduced to 0-20° C. and DCC (dicyclohexylcarbodiimide) isadded to react. The reaction temperature is controlled under 40° C. for4-10 hours. After the reaction is completed, the product is filtered toremove the insoluble dicyclohexyl urea and the filtrate is then washedand separated with 1 mol/L hydrochloric acid. The oil phase is separatedand washed with saturated sodium bicarbonate. The oil phase is againseparated and the solvent is distilled off under reduced pressure toobtain yellow colored crude product. The crude product is than distilledunder reduced pressure again to obtain a colorless transparent product.

Example 19 Synthesis of Curing Agent with a Crosslinking Curing Site

1 mol of diethylenetriamine (DETA), 1-3 mol of methyl isobutyl ketoneare added into reactor and stirred well together solvent, such asbenzene, toluene, xylene, or alkane for azeotropic reaction. After thewater in the water trap reaches the predetermined amount, the solventused and the access ketone are removed under reduced temperature andpressure condition to obtain diethyltriamine ketimine. 100-500 ppm ofpolymerization inhibitor and 1 mol of glycidyl methacrylate (GMA) arethen added to the product to produce the Product J under 60-100° C.condition. The reaction scheme is illustrated in the following:

Example 20 DLP 3D Printing Test Using the Product from Example 19

A solution is obtained by dissolving photoinitiator TPO, lightstabilizer 292, antioxidant 1135 into lauryl methacrylate (LMA) andpolyethylene glycol (600) dimethacrylate (PEG(600) DMA) using Thinky™mixer. TBAEMA-blocked polyurethane prepolymer(TBAEMA-IPDI-PTMO2000-IPDI-TBAEMA and Product J from Example 19 is addedinto the above solution and mixed together to obtain a uniform printingmaterial using Thinky™ mixer. A dog-bone shaped test strip is thenprepared from the above-mentioned printing material using LEAP′ printingtechnology. After the printing, the test strip is first cleaned and thenplaced in water at 60° C. for 30 min, and then in an oven at 120° C. for8 hours to complete thermal curing. A tensile test in accordance withthe ASTM D412 standard shows a 22 MPa tensile strength and a 340% ofelongation break.

Parts by Component Weight TBAEMA-IPDI-PTMO2000- 75 IPDI-TBAEMAPEG(600)DMA 5 LMA 20 Product J from Example 19 10.17 light stabilizer292 0.7 antioxidant 1135 1 photoinitiator TPO 0.5

Example 21 Synthesis of Curing Agent with Asymmetrical Protecting Groups

1 mol of 3,3-Dimethyl-4,4-diaminodicyclohexylmethane (DMDC), 1 mol ofmethyl isobutyl ketone (MIBK) are added into reactor and stirred welltogether solvent, such as benzene, toluene, xylene, or alkane forazeotropic reaction. After the water in the water trap reaches thepredetermined amount, DMDC with MIBK protecting only on one end isobtained. 1 mol Product from Example 17 is added to the for continuousazeotropic reaction. After the water produced reaches the predeterminedamount, the excess solvent is removed through reduced pressuredistillation to obtain Product K.

Example 22 DLP 3D Printing Test Using the Product from Example 21

A solution is obtained by dissolving photoinitiator TPO, lightstabilizer 292, antioxidant 1135 into lauryl methacrylate (LMA) andpolyethylene glycol (600) dimethacrylate (PEG(600) DMA) using Thinky™mixer. TBAEMA-blocked polyurethane prepolymer(TBAEMA-IPDI-PTMO2000-IPDI-TBAEMA and Product K from Example 21 is addedinto the above solution and mixed together to obtain a uniform printingmaterial using Thinky™ mixer. A dog-bone shaped test strip is thenprepared from the above-mentioned printing material using LEAP™ printingtechnology. After the printing, the test strip is first cleaned and thenplaced in water at 60° C. for 30 min, and then in an oven at 120° C. for8 hours to complete thermal curing. A tensile test in accordance withthe ASTM D412 standard shows a 28 MPa tensile strength and a 640% ofelongation break.

Parts by Component Weight TBAEMA-IPDI-PTMO2000- 75 IPDI-TBAEMAPEG(600)DMA 5 LMA 20 Product K from Example 21 14.01 light stabilizer292 0.7 antioxidant 1135 1 photoinitiator TPO 0.5

1. A polymerizable liquid used for producing three-dimensional objectsby methods of additive manufacturing, said polymerizable liquidcomprising: a blocked or reactively blocked polyurethane prepolymer; ablocked or reactively blocked curing agent; and a photoinitiator;
 2. Thepolymerizable liquid of claim 1, wherein said blocked or reactivelyblocked polyurethane prepolymer comprises a polyisocyanate.
 3. Thepolymerizable liquid of claim 1, wherein said blocked or reactivelyblocked polyurethane prepolymer has a structure of Formula (A):

wherein A and R are hydrocarbyl groups, R′ is NH or O, and Z is ablocking group having a reactive epoxy, an alkenyl, an alkynyl, or athiol terminal group.
 4. The polymerizable liquid of claim 3, whereinsaid Z is tert-butyl aminoethyl methacrylate (t-BAEMA).
 5. Thepolymerizable liquid of claim 1, wherein said blocked or reactivelyblocked curing agent has a structure of Formula (A1), Formula (A2), orFomula (A3):

wherein each of R₁, R₂, and R₃ includes a linear or branched C1-C36alkyl, a linear or branched C1-C36 alkylene, an alkenyl, an alkenylene,an aryl, an arylene, a heteroaryl, a heteroarylene, a cycloalkyl, orcycloalkenyl; and each of Y₁ and Y₂ includes a protecting group thatprotects amino groups or hydroxyl groups.
 6. The polymerizable liquid ofclaim 5, wherein said Y₁ and said Y₂ have different structures.
 7. Thepolymerizable liquid of claim 5, wherein said blocked or reactivelyblocked curing agent comprises an imine group, said imine group is asubstituent derived from a reaction of an aldehyde or ketone with anamine.
 8. The polymerizable liquid of claim 5, wherein said blocked orreactively blocked curing agent comprises a carbamate group, saidcarbamate group is a substituent derived from a reaction of a carboxylicacid or carboxylic ester with an amine.
 9. The polymerizable liquid ofclaim 5, wherein each of at least one of said Y₁ or said Y₂ furthercomprises a photopolymerizable group.
 10. The polymerizable liquid ofclaim 9, wherein said photopolymerizable group comprises an acrylategroup or a methacrylate group.
 11. The polymerizable liquid of claim 1,wherein said blocked or reactively blocked curing agent has a structureof Formula (A4), Formula (A5), or Formula (A6):

wherein each of R₄, R₅, and R₆ includes an amino-dialkyl, a C3-C36 aryl,an arylene, a cycloalkyl, or a cycloalkenyl; each of Y₁ and Y₂ aprotecting group that protects amino groups or hydroxyl groups; and Xcomprises a photopolymerizable group.
 12. The polymerizable liquid ofclaim 11, wherein said blocked or reactively blocked curing agentcomprises an imine group, said imine group is a substituent derived froma reaction of an aldehyde or ketone with an amine.
 13. The polymerizableliquid of claim 11, wherein said blocked or reactively blocked curingagent comprises a carbamate group, said carbamate group is a substituentderived from a reaction of a carboxylic acid or carboxylic ester with anamine.
 14. The polymerizable liquid of claim 11, wherein said Xcomprises an acrylate group or a methacrylate group.
 15. A method forforming a three-dimensional object, comprising: providing a printingregion defined by a forming platform and a resin reservoir having aforming surface; filling said printing region with a polymerizableliquid, said polymerizable liquid including a blocked or reactivelyblocked polyurethane prepolymer, a blocked or reactively blocked curingagent, and a photoinitiator; exposing said printing region filled withthe polymerizable liquid to energy to form a solid printing intermediatehaving substantially a same shape as said three-dimensional object;providing energy to said solid printing intermediate to form saidthree-dimensional object.
 16. The method of claim 15, wherein saidblocked or reactively blocked curing agent is contained in said solidprinting intermediate in a cured form.
 17. The method of claim 15,wherein said three-dimensional object comprises a polymer blend, aninterpenetrating polymer network, a semi-interpenetrating polymernetwork, or a sequential interpenetrating polymer network ofpolyurethane and polyacrylate.
 18. The method of claim 15, wherein saidthree-dimensional object comprises a copolymer of polyurethane andpolyacrylate.
 19. The polymerizable liquid of claim 1, saidpolymerizable liquid further comprising: a reactive diluent.
 20. Thepolymerizable liquid of claim 1, said polymerizable liquid furthercomprising: a blocked or reactively blocked diisocyanate.